Davco FUEL PRO 485 Technical Manual
TABLE OF CONTENTS
Applications, Models, and Options....................................... 1
How it Works ...........................................................1
“SEEING IS BELIEVING”® ............................................... 2
Dimensions and Specifications.......................................... 3
E Important Safety Precautions .........................................4
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
120VAC Overnight Heater Installation.................................... 6
Water-in-Fuel Sensor (WIF) Installation ..................................6
12VDC/24VDC Pre-heater Installation ................................... 7
Visual Diagnostics - Air vs. Vapor Bubbles................................ 8
Visual Diagnostics with Clear Cover ..................................... 9
Diagnostic Procedures - Air Leaks ......................................10
Diagnostic Procedures - Check Valve and Heater Testing ................11
Service Procedure - Bypass Valve.......................................12
Filter Change Procedure ...............................................13
Preventative Maintenance .............................................14
Service Part Numbers..................................................15
Warranty Policy ........................................................17
Parts Return Policy ....................................................18
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FUEL PRO 485
TECHNICAL MANUAL FOR DTNA
2018 ©DAVCO Technology, LLC. Last Updated: 05/18/17
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APPLICATIONS, MODELS, AND OPTIONS
FUEL PRO® 485
®
TECHNICAL MANUAL
Applications 2017 engine models
• Detroit DD13, DD15, DD16
• Cummins X15
• New Cascadia
Meets/Exceeds 2017 engine manufacturer’s stringent water separation
requirements
Models and Options
• Base Model - Unheated
• Electric Pre-heater Options
• 12VDC PTC pre-heater
• 120 VAC Overnight heater
• Water-in-Fuel (WIF) Sensor (standard
when used with Cummins X15 Engines)
HOW IT WORKS
• Fuel from the tank enters the Fuel Processor body (suction side of the fuel system).
• Large contaminants and “free” water are separated from the fuel and remain in the body.
• Fuel rises into the clear cover.
• Contaminants and emulsified water are captured by the filter media.
• Fuel level rises to maintain a fuel path through the clean filter media and with lowest restriction.
• Clean, water-free fuel exits the Fuel Processor and flows to the engine fuel module.
Fuel System Diagram
FUEL TO ENGINE
ENGINE LIFT PUMP
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FUEL TO FUEL TANK
FUEL FROM
FUEL TANK
FUEL TANK
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“SEEING IS BELIEVING”®
See when NOT to change the fuel filter.
See the condition of the fuel. Seeing what collects on the filter media or what’s happening inside the clear cover can help
diagnose many fuel and mechanical conditions.
“Filter on Top” configuration. Water and debris removed from the fuel falls to the lower chamber and stays away from the
filter media resulting in longer filter life.
Built in protection when priming the fuel filter. Unfiltered fuel is kept on the “dirty” side of the filter media during priming
ensuring only clean fuel reaches the engine.
Patented media. The “Best in Class” StrataPore™ media removes 98% of free and emulsified water over the life of the filter.
This far exceeds the performance of cellulose media.
TECHNICAL MANUAL
When new, the fuel level in the filter will be very low
with minimal restriction. As the filter is used, contami-
nants collect on the filter from the bottom up. Fuel rises
on the filter indicating remaining filter life.
Fuel level at filter wrap level. Even though the fuel level
is now more than half of the filter element, the fuel is still
flowing through clean media at minimal restriction levels.
The filter still has significant life remaining.
Fuel level increases in clear cover. As contaminants
collect on the filter, the fuel rises to a non-contaminated
section of the filter, providing optimal filtration while
maintaining lowest restriction.
The filter element is now completely covered by fuel.
At this point, all of the media’s surface area is utilized.
Restriction is increasing and the filter element should be
changed at the next scheduled maintenance interval.
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TECHNICAL MANUAL
DIMENSIONS AND SPECIFICATIONS
All dimensions are in inches (millimeters)
FUEL PRO® 485
RIGHT VIEW TOP VIEW
FRONT VIEW LEFT VIEW
SPECIFICATIONS
Height Overall 15.54 in.
Depth Overall 10.34 in.
Width, Max. 11.62 in.
Weight, Dry 10.35 lbs
Fuel In Connection M22 x 15-6H
Fuel Out Connection M22 x 15-6H
Filter Service Clearance Min. 5.5 in.
Max. Fuel Flow 180 gph
Electric Pre-heater 12VDC (155W or 195W) or
24VDC (195W)
Overnight heater 120VAC, 75 W, .65 A
FILTRATION PERFORMANCE AT 174 GPH
Micron 8
Coarse water removal (%) >99%
Emulsified water removal (%) >93%
% Emulsified water removal (end of life filter) >80%
Dirt holding capacity (grams) 150
2.00
1.80
1.60
1.40
1.20
1.00
0.80
0.60
0.40
0.20
0.00
0 50 100 150 200 250
Differential Pressure (in-Hg)
Restriction vs. flow
Flow (gph)
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FUEL PRO® 485
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E IMPORTANT SAFETY PRECAUTIONS
Preventative Maintenance
Environmental Concerns and Seasonal Maintenance
• Steam clean the DieselPro with fresh water regularly to keep corrosive salt or dirt from building up on the housing, cover
and collar.
• Extreme winter or salt corrosion environments may require lubrication of the collar with anti-seize lubricant every 180 days.
Weekly water drains
1. Turn off the engine and remove the vent cap.
2. Place a suitable container under the DieselPro and open the drain valve.
3. Collected water will flow into the container. When fuel begins to flow out the drain, close the drain valve. Drain the least
amount of fuel as possible.
4. Install the vent cap and tighten it by hand until it clicks.
5. Start the engine and raise the RPM for one minute to purge the air from the system.
During each filter change
• Change the o-rings on the cover and vent cap (included with the service filter kit).
Annual inspection
• Inspect all electrical connections for corrosion.
• Inspect all fuel fittings for leaks.
• Inspect the DieselPro for damage or signs of leaks.
TECHNICAL MANUAL
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INSTALLATION INSTRUCTIONS
Installation Location
The FuelPro must be installed between the fuel tank and the
fuel transfer pump. In some cases, the FuelPro can be used
as the only fuel filter in the system. This is generally dependent on the engine model year. Consult the engine manufacturer for their recommendation.
Mounting the FuelPro
• Do not install the FuelPro directly on the engine.
• Mount vertically with the cover and element pointing up.
• Make sure there is enough top and side clearance for the
cover to be conveniently removed for filter replacement.
• The FuelPro MUST be installed so that the filter element
is above the "FULL" level of the fuel tank.
E The ignition key must be in the off position, unless oth-
erwise directed. To avoid unintentional engine startup,
use a lockout key and/or signage to alert personnel
that work is being performed. Chock the wheels.
1. With the engine shut down and at ambient temperature,
close the fuel shutoff valve (if equipped) and place a suitable container under the fuel filters.
2. Remove the primary fuel filter element assembly,
sedimenter, and/or water separator. Drain the used
element and dispose of it in an environmentally responsible manner, according to state and/or federal (EPA)
recommendations.
Fuel Line Routing
To minimize fuel system restriction, observe the following
guidelines when plumbing the fuel system:
• Keep the fuel line routing as smooth as possible with no
low-hanging loops which can trap water.
• Use 90° elbows only when necessary.
• If the fuel hoses are cut to length on the job, be sure that
the inner liner of the fuel hose is not cut by the fitting,
which can cause check valve performance issues. Make
sure hoses are clean and free of debris before installing.
• To avoid damaging the aluminum FuelPro body, do not
over-tighten fuel lines or fuel line fittings.
FUEL PRO® 485
TECHNICAL MANUAL
FUEL IN
FUEL OUT
1. Route the fuel supply line from the pick up on the fuel
tank to the FuelPro inlet (labeled “FUEL IN” on figure
below, not labeled on housing).
2. Route the fuel outlet line from the FuelPro outlet (labeled
“FUEL OUT”) to the inlet of the fuel pump.
Priming the Fuel System
1. Check to make sure the drain valve at the base of the
FuelPro is closed.
2. Remove the vent cap from the top of the clear cover. Fill
the FuelPro full with clean fuel. Re-install the vent cap.
Tighten the vent cap by hand until it clicks.
3. Start the engine. When the lubrication system reaches its
normal operating pressure, increase engine RPM to high
idle for one to two minutes. After the air is purged loosen
the vent cap until the fuel level lowers to just above the
collar. Tighten the vent cap by hand until it clicks.
4. Apply downward pressure on the top of the cover and
rotate the collar until contact.
5. Use a DAVCO wrench if necessary to tighten 3 additional
ribs..
The clear filter cover will not fill completely during engine
operation. It will gradually fill over time and the fuel level will
rise as the filter becomes contaminated.
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